Published by
Siemens AG 2016
Power and Gas Division
Steam Turbines
Freyeslebenstrasse 1
91058 Erlangen, Germany
For more information, please contact
our Customer Support Center.
Phone: +49 180 524 70 00
Fax: +49 180 524 24 71
(Charges depending on provider)
E-mail: [email protected]
Article-No: PGSU-B10015-00-7600
Printed in Germany
Dispo 34808
BR 1116.10 TB.I1116 V1
Subject to changes and errors. The information given in this document
only contains general descriptions and/or performance features which
may not always specifically reflect those described, or which may
undergo modification in the course of further development of the
products. The requested performance features are binding only when
they are expressly agreed upon in the concluded contract.
The powerful
potential of
sugarcane
Turning biomass into profit with
Siemens steam turbines
siemens.com/steamturbines
The powerful potential of sugarcane
The powerful potential of sugarcane
A taste of
independence
Creating your own source of energy from bagasse
Creating green, CO₂-neutral energy from bagasse requires the
highest levels of efficiency. The goal of any plant is to extract as
much natural energy as possible, whether that energy is sugar
itself or steam and power to be sold to the grid. By choosing and
using the right equipment, manufacturers can reap huge financial
rewards and feel good about running a sustainable operation that
is fit for the future. Cogeneration – the ability to create two forms
of energy from a single fuel source – has many benefits, both on
a local and global level.
The benefits of cogeneration
Increase profitability
Take advantage of domestic resources to increase your profits
and boost your competitiveness. There are many successful
subsidiaries operating around the world.
Renewable and CO₂-neutral
Bagasse is renewable and does not
emit greenhouse gases.
Support the national grid
Sell power back to the grid and contribute
to the bioenergy targets of your country.
Bagasse is the residual fiber left over from the sugarcane
extraction process. Instead of treating it as waste, sugar
mills can repurpose it to produce heat and electricity,
in turn boosting independence and profit without
creating more greenhouse gases.
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The powerful potential of sugarcane
The powerful potential of sugarcane
A surge of power
The right turbine for your plant
With over a century of experience in
turbine technology, Siemens has
delivered solutions for a wide range of
purposes. For the sugar industry,
turbines of up to 50 MW are the most
relevant. Whether you run a small,
medium, or large mill, we have the
best-fitting and easily maintainable
solution to match your needs.
Small sugar mills
up to
5 MW
2,000
S
tons of sugarcane crushed per day (tcd)
Rely on our proven portfolio
For small sugar mills, there is the SST-60. For larger sugar mills, we have the
popular SST-300. Whatever size mill you operate, we have a proven, easily maintainable turbine that is ready to fulfill your needs.
Power output in MW of our steam turbines
SST-040
0.45–0.7
SST-050
up to 0.75
SST-060
up to 6
SST-110
up to 8
SST-111
up to 12
SST-150
20
Medium-size sugar mills
For most mills, the popular SST-300 is the ideal choice.
Turn to the last page of this brochure to learn more.
up to
20 MW
6,000
10
SST-200
M
L
tons of sugarcane crushed per day (tcd)
50
SST-300
Your benefits at a glance
65
SST-400
100
SST-500
Large sugar mills
150
SST-600
up to
52 MW
20,000
L
tons of sugarcane crushed per day (tcd)
4
0
30
60
90
120
150
Enhanced efficiency
With their improved blade and seal
concept, Siemens steam turbines are
highly efficient in operation. Each
turbine is characterized by a simple
modular construction that provides
flexibility and ease during configuration
and maintenance, ensuring maximum
output in the least time possible. The
result is more energy produced and
fed into the grid, and thus more profit.
Proven reliability and availability
Calling on a century of turbine development, all Siemens turbines guarantee a long life cycle of 200,000 hours.
High availability is the result of a
proven design, comprised of pressure
blades with reliable root clamps and
maintenance-free bolts. By lowering
maintenance costs and being ready to
crush whenever necessary, your mill
will become more sustainable and
profitable.
Minimal inspection required
All Siemens turbines feature a compact
design and simple layout. This significantly reduces the cost and time
associated with construction, inspection,
and maintenance, enabling sugar
producers to run a more efficient and
independent plant.
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The powerful potential of sugarcane
The powerful potential of sugarcane
Boost the efficiency
of your business
Flexible solutions for tailored performance
Part-load operation
In order to harvest as much sugarcane as
possible during the production season,
steam turbines must operate with high
reliability and availability. Each day offline
can cause huge losses. Not every mill always
runs under full load, and bagasse can differ
in its moisture and ash content, resulting in
an inconsistent steam parameter. To solve
this, part-load operation optimizes the
efficiency and power output of the turbine
if there is not enough sugarcane to crush.
This feature ensures consistent results from
season to season.
Homogeneous geometrical casing design
This innovative design approach means
Siemens turbines provide distinct benefits.
• Quick start times (up to 50 percent faster)
Our tailor-made solutions aim to boost output while
reducing costs and resources used. This allows sugar
producers to be more independent, sustainable, and
profitable.
• Fast load changes – full load or partial load
Back pressure or condensing
Siemens turbines are available for back
pressure or condensing operations in singleor multistage designs. To meet your specific
needs, they can also be equipped with single
extraction options, or multiple controlled
(pass-out) and uncontrolled (bleeding)
extraction options.
Steam extraction
During controlled and uncontrolled extraction,
steam is released from various stages of the
turbine and used for industrial processes, or
sent to boiler feedwater heaters to improve
overall cycle efficiency. To ensure you have
a tailor-made turbine solution, Siemens
provides controlled and uncontrolled extraction when you need it. Our experts will help
you find the optimum balance between high
efficiency and low cost.
• High efficiency
Condensing
Back pressure
Single-stage turbines
Multistage turbines
Application
Condensing turbines are most commonly found in
electrical power plants. These turbines receive steam
from a boiler and exhaust it to a condenser.
The exhausted steam is at a pressure well below
atmospheric, and is in a partially condensed state,
typically of a quality near 90 percent.
Application
Back pressure turbines are most widely used for process
steam applications. The exhaust pressure is controlled
by a regulating valve, which adapts to the needs of the
process steam pressure.
The speed of single-stage steam turbines is notably
higher than the speed of the driven equipment and
they are therefore equipped with integral gearboxes.
Integral gearing keeps the turbine relatively small,
enabling minimal floor space requirements. Another
advantage is that they allow the turbine rotor to operate at high speed, which is key to superior efficiency.
Siemens’ multistage steam turbines are designed with a
customized steam path. The portfolio uses reaction
blade technology. The fixed casing design of the predesigned machines enables high performance at lower
cost together with short delivery lead and commissioning times.
When to apply
Requires a bigger investment but is more efficient.
Applicable if feed-in tariff is high and there are good
subsidies.
These are commonly operated where large amounts of
low-pressure process steam is needed.
When to apply
More cost-effective but less efficient, applicable if the
government gives no subsidies and power price is very
low.
Depending on a customer’s specific requirements, either condensing or back pressure turbines can be used in the
sugar-making process. Both turbine types have a long and proven track record in the industry, and each provides
a tailored solution that can support any plant.
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The powerful potential of sugarcane
The powerful potential of sugarcane
Siemens: fueling
the future of sugar
Tradition meets innovation
Our recipe for success
In today’s sugar industry, increasing competition and the need for higher efficiency
means producers are looking for new ways
to achieve long-term success. And this is
exactly where Siemens comes in. With
unparalleled understanding of sugar production, a global footprint, and the most
extensive range of products, solutions, and
services, we are here to help you succeed.
Siemens has been developing solutions for
the sugar industry for well over half a
century. We are very familiar with the
processes and objectives involved, as well
as the challenges that producers face. Our
work aims to boost output with reduced
expenditure and resources, allowing you to
acquire greater independence, sustainability,
and profit in the future.
Generators made with
generations of expertise
Siemens offers a comprehensive portfolio of
generators for the 25 to 2,235 MVA power
range. They achieve efficiency levels of up
to 99 percent. The design of our generators
benefits from more than 150 years of experience in development and production since
Werner von Siemens invented the electrical
generator in 1866. Generators of our SGenTM
series are in operation around the globe,
with an installed fleet of more than 2,500
units. Assembly and testing specialists
accompany our generators from the planning stage to destination, where they put
them into operation for you. In addition, our
specialists service generators from around
the world and perform upgrades and repairs
– even for components from other manufacturers.
Each step of the sugar production process must run
smoothly. Siemens has a proven portfolio of steam
turbines, from small to large, so you can choose a
precise solution for your plant.
Your proven global partner
The wider Siemens world provides 360-degree
support for any plant. With an industryspecific portfolio ranging from automation,
instrumentation, drive technology and
low-voltage switchgear, as well as global
services throughout the entire life cycle of
the plant, we cover every area of your sugar
production to ensure that processes are
efficient, coordinated, and centralized.
What you get when you choose Siemens
• Years of proven experience in the industry
• Specialist support from start to finish
• An all-in-one solution for any plant
• Cost-effective packaging
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If preferred, we remove the need to deal
with third parties and provide everything
from under one roof; at the same time we
can provide single components only, such as
the steam turbine. We are as flexible as you
need to be. When you choose Siemens, you
have access to many different components,
such as boilers and condensers. With a rich
history that dates back over a century and
new innovations in the making, the Siemens
name will be your trusted partner now and
in the future.
Our boiler partners
When you choose Siemens, you gain access
to several leading boiler producers. To help
you understand what is on offer, consider
one of our partners, NEM Energy BV, a
subsidiary of Siemens (NEM). NEM creates
custom-made heat recovery steam generators (HRSGs), industrial and utility boilers,
and related equipment. With over 80 years
of experience and 815 HRSGs installed
across six continents, NEM is a leading
solutions provider for refineries, the petrochemical industry, and more. NEM provides
various types of steam generators using
gaseous, liquid, and solid fuels which include biomass such as sewage sludge and
sugarcane residues. By choosing NEM, you
can further enhance your plant and benefit
from the specialist support of Siemens.
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The powerful potential of sugarcane
The powerful potential of sugarcane
Becoming self-sufficient
1. Sucrerie de Wonji Shoa, Ethiopia
Global expertise,
local solutions
2. Simbhaoli Sugar Ltd., India
3. Shivratna Udyog Pvt. Ltd., India
1
Sucrerie de Wonji Shoa
Ethiopia
4. Shree Krishna Khandsari, India
5. Gammon India Ltd., India
Our latest references at a glance
6. NSL Sugar Ltd., India
Year: 2013
7. Ponni Sugars, India
Steam turbine: SST-300
8. Mitr Phol, Thailand
Power output: 31.5 MW
9. Khanh Hoa (Cam Ranh), Vietnam
Inlet steam pressure: 62 bar(a) / 899 psi
At Sucrerie de Wonji Shoa, a sugar mill
located 100 km east of Addis Ababa in
Ethiopia, self-sufficiency is a key
objective. After processing sugarcane,
the remaining bagasse is used as fuel
for the boiler. The mill operates with a
capacity of 31.5 MW, which produces
enough energy to fully cover the
demand for electricity and process
steam.
Inlet steam temperature: 515 °C / 959 °F
Powering innovation
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2
Simbhaoli Sugars Ltd.
India
Year: 2013
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4
Steam turbine: SST-300
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3
Power output: 18 MW
There’s more to Simbhaoli Sugars Ltd.
than the name suggests. The company
specializes in sugar, of course, but also
liquor, technology consultancy, cogenerated power, extra neutral alcohol
(ENA), ethanol, and bio-manure. As
India’s largest integrated sugar refinery,
it is a pioneer of innovative refinery
processes, backed by the power of the
SST-300.
Speed: 6,800 rpm
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Inlet steam pressure: 87 bar(a) Inlet steam temperature: 510 °C / 950 °F
8
Exhaust steam pressure: 0.1 bar(a) Capacity: 5,000 tcd
1
Looking for a partner
3
Shivratna Udyog Pvt. Ltd.
India
The SST-300 – a success story
around the world
22.4 million*
operating hours
Steam turbine: SST-300
Power output: 12 MW
Speed: 8,300 rpm
11,800 MW
*
fleet experience in all regions
100
Year: 2015
*
Inlet steam pressure: 72 bar(a) When Shivratna Udyog Pvt. Ltd. started looking for a new steam turbine,
quality and reliability were top priorities. “We found Siemens to be always
approachable, quality-conscious,
safety-conscious, and customer-oriented throughout the execution of the
project. We are very much satisfied
(…) and would recommend other
prospective customers to prefer
Siemens over other options,” commented the plant’s general manager.
Inlet steam temperature: 510 °C / 950 °F
Exhaust steam pressure: 3 bar(a) Capacity: 2,500 tcd
SST-300s installed in sugar mills in
Southeast Asia, Africa, and Latin America
*as of 2015
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The powerful potential of sugarcane
The powerful potential of sugarcane
Freedom to grow
4
Shree Krishna Khandsari
Sugar Mills
India
Year: 2005
Steam turbine: SST-050
Power output: 2 MW
Founded in 1973, Shree Krishna Khandsari Sugar Mills began life crushing
200 tcd. Since installing the SST-050
turbine in 2005, its output has reached
1,100 tcd. Today, the plant is totally
independent from the state grid, which
is plagued by frequency fluctuations
and power outages. Calculations show
that by using the SST-050, the company
saves 1.8 million Indian rupees per
month compared to other options.
Fuelling world firsts
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Ponni Sugars
India
Year: 2010
Steam turbine: SST-300
Power output: 19 MW
This sugar mill has a special place in
history: it was the first to successfully
produce newsprint from sugarcane
bagasse. It continues to pioneer firsts
in the industry, such as using alternative fuel in its boilers. In 2010, the
plant chose Siemens to deliver an
SST-300 turbine, which today generates 19 MW of power – enough to keep
the innovations coming.
Speed: 6,800 rpm
Exhaust pressure: 1.5 bar(a) Inlet steam pressure: 111 bar(a) Capacity: 1,100 tcd
Inlet steam temperature: 520 °C / 968 °F
Exhaust steam pressure: 0.1 bar(a) Capacity: 2,500 tcd
Upping the power
5
Gammon India Ltd A/c. Pravara
Renewable Energy Ltd.
India
Year: 2012
Steam turbine: SST-300
Operating as a subsidiary of Gammon
Infrastructure Projects Limited, Pravara
Renewable Energy Ltd. owns and
operates a bagasse-fuelled cogeneration power project that processes
roughly 5,000 tcd. By choosing Siemens
and installing an SST-300 steam turbine in 2012, the plant now operates
at a capacity of 30 MW.
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Award-winning
energy saving
Mitr Phol
Thailand
Year: 2010
Steam turbine: SST-300
Power output: 30 MW
Established in 1946 as a small family
business, Mitr Phol is now a global
enterprise with footprints in China,
Laos, Australia, and elsewhere. The
company has cared for the environment for over 55 years, and has received prestigious national and international awards for its energy-saving
efforts along the way. Today, the plant is
powered by an SST-300 from Siemens.
Power output: 26 MW
Speed: 6,800 rpm
Inlet steam pressure: 107 bar(a) Inlet steam temperature: 535 °C / 995 °F
Exhaust steam pressure: 0.11 bar(a) Capacity: 5,000 tcd
There on time
6
NSL Sugar Ltd.
India
Year: 2010
Steam turbine: SST-300
Power output: 35 MW
Speed: 6,800 rpm
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NSL Sugar Ltd. (NSL) is one of the most
efficient integrated sugar companies
in southern India. To help boost this
status, the company turned to a
Siemens SST-300 steam turbine in
2010. S.C. Gupta, consultant at NSL
Sugar Ltd., said: “We are highly satisfied with the support provided by
Siemens … [the team] completed the
project on time, and certain activities
were completed ahead of schedule.”
Future-proof production
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Khanh Hoa (Cam Ranh)
Vietnam
Year: 1999
Steam turbine: SST-300
Power output: 25 MW
Located in the Cam Lam district in the
coastal Khanh Hoa province, Khanh
Hoa handles roughly 3,000 tcd. In the
late 90s the plant was looking for a
reliable, high-quality steam turbine
solution to power production into the
future. Since choosing the SST-300
from Siemens, the plant has not performed a major overhaul or changed
any major parts in the past 17 years.
Speed: 7,161 rpm
Inlet steam pressure: 106 bar(a) Inlet steam pressure: ≤ 46 bar(a) / 667 psi
Inlet steam temperature: 535 °C / 995 °F
Inlet steam temperature: ≤ 450 °C / 842 °F
Exhaust steam pressure: 0.1 bar(a) Exhaust pressure: 2.5 bar(a) / 36.3 psi
Capacity: 7,500 tcd
Capacity: 3,000 tcd
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The powerful potential of sugarcane
The powerful potential of sugarcane
Siemens SST
steam turbines
A solution for every sugar mill
SST-300
Made with best-in-class technology and 20
years of development expertise, the SST-300
is a versatile and proven turbine solution. In
the last decade alone, it has been installed in
over 500 industrial and power applications
across the world. All components and auxiliaries, including the lubricating oil system,
are mounted on a common base frame. The
turbine can be configured with either an
upward, downward, or axial exhaust orientation, and can also accommodate multiple
extraction/steam induction points. Its compact design and simple layout significantly
reduces the cost and time associated with
construction, inspection, and maintenance.
Exhaust
Rotor and reaction blading
Turbine casing
Gearbox
Base frame
SST-200
The SST-200 is a single casing steam turbine
in packaged and skid-mounted design. The
back pressure and condensing turbines,
with and without extraction or bleed points,
are characterized by a robust layout. For
generator drive an epicyclic gearbox combined with the generator is preferred, since
this provides high efficiency together with a
very compact arrangement.
Back pressure and condensing turbines are
available with upward or downward exhaust
and with internally controlled extraction and
the possibility of several bleeds allows the
selection of optimal solutions for the industrial applications.
Power output: up to 10 MW
Speed: up to 14,600 rpm
Live steam conditions
(nozzle or throttle control):
Uncontrolled extractions:
Pressure up to 25 bar(a) / 365 psi
• Inlet pressure up to 110 bar(a) / 1,595 psi
Controlled extraction possible (up to 4):
Pressure up to 16 bar(a) / 230 psi
Temperature up to 350 °C / 560 °F
Exhaust steam pressure:
SST-150
The SST-150 is a single-casing steam turbine,
providing geared drive to a 1,500 or 1,800
rpm generator. The turbine is packaged in a
skid-mounted design (can also be with
separate oil system). This is a very compact
arrangement which provides high efficiency
in power generation and mechanical drive
applications. The pre-designed turboset
enables early planning of the turbine building layout, saving time for the customer.
The turbine is used for both back pressure or
condensing applications with internally
controlled extraction and scope for several
bleeds. Both back pressure and condensing
turbines are available with upward or downward exhaust.
The turbine casing and casing components
are designed to permit short start-up times.
The entire package is assembled and wired
in the workshop prior to delivery.
• Temperature up to 520 °C / 970 °F
• Back pressure up to 10 bar(a) / 145 psi
• Condensing up to 0.6 bar(a) / 8.7 psi
Power output: up to 45 MW
Speed: up to 12,000 rpm
Live steam conditions
(nozzle or throttle control):
Power output: up to 20 MW
Speed: up to 13,300 rpm
Inlet steam parameter:
Uncontrolled extractions (up to 6):
Pressure up to 60 bar(a) / 870 psi
• Pressure up to 120 bar(a) / 1,740 psi
Uncontrolled extractions:
Pressure up to 25 bar(a) / 365 psi
• Inlet steam temperature up to 505 °C / 940 °F
Controlled extraction possible
(single or double, adaptive stage, nozzle
control, throttle control):
Pressure up to 25 bar(a) / 362 psi
Exhaust steam pressure:
• Temperature up to 540 °C / 1,004 °F
• Back pressure up to 16 bar(a) / 232 psi
• District heating up to 3 bar(a) / 43 psi
Controlled extraction possible (up to 4):
Pressure up to 16 bar(a) / 230 psi
Temperature up to 350 °C / 560 °F
• Inlet steam pressure up to 103 bar(a) / 1,495 psi
Exhaust steam pressure:
• Back pressure up to 10 bar(a) / 145 psi
• Condensing up to 0.25 bar(a) / 3.6 psi
• Condensing up to 0.25 bar(a) / 3.6 psi
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